Prefabricated wall panel



y 1941- E. s. HARMAN 2,240,774

PREFABRICATED WALL PANEL Filed Sept. 29, 1939" 2 Sheets-Sheet 1 XI H . I h 0 Ag 69 Yr 4317} mi m C EUGENE 6. HARMAN May 6, 1941. E. s. HARMAN PREFABRICATED WALL PANEL Filed Sept. 29, 1939 2 Sheets-Sheet 2 v w 1 H EUGENE 6. HARM/1N Patented May 6, 1941 UNITED STATES PATENT OFFICE PREFABRICATED WALL PANEL Eugene S. Harman, Chicago, 111.

Application September 29, 1939, Serial No.- 297,087

2 Claims. (Cl. 72-43) This invention relates to a prefabricated wall panel and to a method of assembling a plurality of such panels into a wall construction.

According to the present invention, there is provided a prefabricated wall panel comprising a backing sheet, keying material secured to the backing sheet and an initially plastic composition keyed to and molded about the keying material. The plastic composition is molded in the form of blocks, with the blocks arranged in spaced relationship in courses and with the blocks in adjacent courses staggered as is customary in brick, stone, terra cotta and other masonry wall construction. In order to further simulate masonry wall construction, the spaces between the molded blocks and between the courses of such blocks are filled with mortar, or other suitable binding material. The mortar also serves to overlie and conceal the joints between the prefabricated panels when the panels are assembled into the proper relationship to constitute a wall.

In order to facilitate the assembling of my prefabricated panels, the marginal edges of the panels may be slightly ofiset so as to overlap one another, or they may be inwardly flanged for joinder together by bolts, rivets, clamps, or the like. Portions of the blocks simulating bricks, or other types of masonry, are omitted from at least one course adjacent the vertical marginal edges of each panel so as to permit the marginal edges of adjacent panels to be secured together more easily at those points. This arrangement also makes it unnecessary to have certain of the molded blocks in the staggered courses extend beyond the marginal edges of the panels, or to join half blocks at the meeting edges of adjacent panels. Instead, individually formed blocks are inserted in the mating half block spaces, formed when the panels are erected, and such individual blocks are secured in place so as to overlie the meeting edges of the adjacent panels and to complete the otherwise incomplete courses of the panels. Mortar is then laid in the joints between the adjacent panels and also in the spaces around the individual blocks, so that the Wall, when finished, very closely simulates ordinary types of masonry, such as brick, stone, terra cotta, and the like.

It is therefore an important object of the present invention to provide a prefabricated wall panel embodying novel features of construction that enable it to be manufactured at a relatively low cost and that facilitate its erection to form a wall structure that may simulate any one of a number of types of masonry wall construction.

It is a further important object of this invention to provide a prefabricated wall panel of a veneered construction that simulates masonry and that may be manufactured and installed at a. considerable saving, as compared with the cost of the usual masonry wall construction.

It is a further important object of this invention to provide a method of assembling prefabricated panels to form walls simulating the appearance of masonry walls.

Other and further important objects of this invention will be apparent from the disclosures in the specification and the accompanying drawings.

This invention (in a preferred form) is illustrated in the drawings and hereinafter more fully described.

On the drawings:

Figure 1 is a fragmentary elevational view of a finished wall construction employing panels embodying my invention.

Figure 2 is a fragmentary sectional view taken substantially along the line IIII of Fig. 1.

Figure 3' is an enlarged elevational view of a single prefabricated panel.

Figure 4 is a further enlarged, fragmentary elevational view of a plurality of assembled panels prior to the insertion of an individual block to complete the assemblage, and with parts broken away to show the construction more clearly.

Figure 5 is an elevational view of the inner face of an individual block for insertion into the space shown in the panel assembly of Fig. 4.

Figure 6 is an enlarged, fragmentary sectionalview taken substantially along the line VIVI of Fig. 4, but with the individual block of Fig. 5 secured in place therein.

Figure 7 is a fragmentary sectional view taken substantially along the line VII-VII of Fig. 6.

Figure 8 is an enlarged, fragmentary sectional View taken substantially along the line VIII-VIII of Fig. 4, with the individual block of Fig. 5 in its finished assembled relationship.

Figure 9 is a fragmentary sectional view taken substantially along the line IX--IX of Fig. 8.

Figure 10 is a fragmentary enlarged sectional view taken substantially along the line X-X of Fig. 4.

Figure 11 is an enlarged, fragmentary view taken substantially along the line XII-XI of Fig. 4.

Figure 12 is an enlarged fragmentary sectional view taken substantially along the line XII-XII of Fig. 3.

As shown on the drawings:

The reference numeral 20 indicates a finished wall construction, of which a corner only is shown in Figs. 1 and 2. Said wall construction 20 comprises a wooden frame wall, indicated generally by the reference numeral 2| and consisting of vertical studding 22, corner post 23 and inner wall sheeting 24. To the outer surfaces of the studding 22 and corner post 23 are secured prefabricated panels, such as the panel 25 (Fig 3), to provide a continuous outer wall facing 26. It will be understood that the construction of the wooden frame wall 2| has not been completely shown and that it may be of any conventional design such as used in wooden frame houses and other buildings.

Each of the panels 25 (Fig. 3) in its preferred prefabricated state, comprises a backing sheet 21, which may suitably be formed of relatively light gauge sheet steel, wood or composition board, or other sheet material having the requisite strength and rigidity. Keying material, represented generally by the reference numeral 28, such as metal lath, expanded metal, metal netting or other reticular material, is secured to the backing sheet 21, as by means of fasteners 29, which as best shown in Fig. 11 may suitably comprise bolts 30 extending through the backing sheet 21 and expanded metal lath 28 and having a nut 3i threaded against a metal strip or Washer 32. The backing sheet 2'! may be countersunk, as at 33, to accommodate the head of the bolt 30, while the nut 3| serves to hold the metal strip or washer 32 against the expanded metal lath, or other keying material 28.

Each of the panels further-comprises a veneer or facinglayer of compositionmaterial that is applied to the keying material 28 in an initially plastic form and that is molded into the stripsof the form corresponding with the width of the spaces between the blocks 34. The expanded metal lath 28, or other keying material is laid over this form and the plastic composition poured through the metal lath into the form.

After the pockets of-the form have been filled to provide the lower block layers 35, a similar form is laid on top of the expanded metal lath and a further. quantity of plastic composition poured therelnto to provide the upper block layers 36. After the plastic composition has set, the forms are removed, and the sheet of expanded metal lath supporting the molded blocks again placed on a backing sheet 21 and secured thereto by means of the fasteners 29. Mortar is next poured into the spaces between the molded blocks. The same forms may then be used to press the mortar into place and key it to the expanded metal lath 28. As a result, lines of mortar 58 fill in the spaces about the blocks 34. The marginal edges of the metal lath 28, however, project beyond the outer rows of blocks 34 and are not covered with mortar until the panels are erected on the job.

When the blocks are molded as above described, the lower layer 35 of a block 34 may be made of a different composition than the upper layer 35. but both layers are keyed to the expanded metal lath 28, or other keying material Preferably, both layers 35 and 36 are relatively thin, with the layer 35 of equal or less thickness than the layer 36 so as to reduce the weight of the panel and also its cost of manufacture. Suitable cementitious compositions for use in the molding or casting of the facing blocks 34 may comprise mixtures of silica, magnesite and asbestos for the top layer, with a similar but less expensive composition for the lower layer. The plastic composition may also be composed of pulverized blast furnace slag, with a suitable admixture of fillers or other material. Granite, limestone, terra cotta, or other form of masonry may be readily imitated by the use of suitable compositions.

In the preferred form of the panel 25, the blocks 34 in complete courses 0 are staggered with respect to the blocks in the incomplete courses C, to simulate the appearance of brick, or other type of masonry. Such an arrangement requires that the end blocks in alternate courses C extend beyond the end blocks of intervening courses C. It would not be so feasible to finish out the intervening courses C with a half block, since that would mean matching the half blocks to extend slightly inwardly into the spaces S to afford a key for the mortar or other binding material to be laid therealong, as will be hereinafter more fully explained.

One end edge of the backing sheet 21 is offset,

as at 39, and an adjacent lateral edge is offset,

as at El (Fig. 3), so that when the panels 25 are assembled, the marginal edges of one panel will extend beneath the corresponding offset edges of an adjacent panel (Figs. 4 and 10). The thus overlapping marginal edges are provided with apertures 43, through which nails 4| or other securing devices can be inserted into the studding 22 or other portion of the wooden frame of thewall structure; Where the supporting frame is of steel or metal, rather than of wood, the metal frame may be provided with threaded bolt holes and bolts may be used for anchoring the backing diate courses C. There is thus formed a full sizev space into which is secured an individual block, such as the block 42 shown in Fig 5. Means are provided on the backing sheet 21 within the space so formed for attaching the individual blocks 42,- said means comprising a pair of opposed spaced clips 43, extending inwardly from the long edges of the space near one end thereof, and a slotted clip' 44 extendinginwardly from the shorter opposite end ofsaid space, Each of said clips-43 comprises a metal strip, or the like, attached at one end to the backing sheet 21 and having a free end 45 offset therefrom to extend in spaced parallel relaticnship to thesurface of the backing sheet. Each of the clips at comprises a broader strip of metal secured to the backing sheet 21, as by means of rivets or bolts it, and having an offset inwardly extending portion ll in spaced parallel relationship to the surface of the backing sheet 21. Said offset portion 41 is preferably provided with a slot 48 that extends longitudinally of the length of the space S, S.

Each of the individual blocks 42 comprises a backing strip 49, which may be of cementitious material, to the front surface of which is attached a block 42 which may be similar in composition and, appearance to the blocks 34. A transversely extending clip is secured to the underface of the backing strip 49, as by embedding an offset end 52 thereof in said backing strip 49. Prongs 53 are struck upwardly from the clip 5! in the direction of the undersurface of the backing strip 49. The relative positioning and arrangement of the clip 5| and of the clips 43 are such that when an individual block 42 is inserted in the space S, S, the clip 5i passes under the offset free ends d5 of the clips 43 and the prongs 53 pass beyond and engage the edges 54 of said clips is (Fig. 6).

Each of said individual blocks 52 also carries a clip 55 for interengagement with a clip M. Each of the clips 55 is attached to the undersurface of the backing strip 19 (Fig. 5), as by embedding an offset portion 56 thereof in said backing strip. The main portion of each clip 55 is provided with a longitudinally extending ridge or bead 5?, which, when the individual block is inserted in place, passes into the longitudinally extending slot 48 of a clip 44. The main body portion of the clip 55 thus enters in back of the offset portion ii of the clip M, while the ridge or beading 5T slips into the groove 48 to center the individual block G2. By sliding each individual block '52 endwise into the designated space S, S, interengagement of the several clips can be effected at one time and the individual blocks securely fastened in place in the proper spaced relationship to the adjoining blocks it.

At the point of erection of the panels 25, after individual blocks 52 have been secured in place, mortar is forced into the spaces on all four sides of each of said blocks and is securely keyed therein by reason of the fact that the mortar extends about the projecting marginal portions 59 of the keying material 28 and also extends under all four edges of the individual blocks 62, as at 66 (Figs. 7, 8 and 9). Mortar is also laid along the horizontally and vertically extending joints-be,

tween adjacent panels 25 and the mortar is there keyed to the projecting marginal edges of the backing material 28. 7

It is thus apparent that when a wall construction 29, made up of panels 25 and individual blocks 42, is in its finished form, the wall simulates the appearance of masonry. As illustrated in the drawings, the wall presents the appearance of a brick wall made in the usual way from whole brick, but it is obvious that the blocks 34 and 42 may be of such shape and composition as to simulate limestone, terra cotta, or other type of masonry. The blocks may be made of the same color or in different colors, and waterproof compositions may be employed, if desired.

When used over wood frame structures, each of the panels 25 is lapped with respect to adjacent panels on all four sides. This is accomplished by offsetting the marginal edge of the backing sheet, as at 39 and BI (Fig. 3). The provision of the spaces S in the prefabricated panels gives access to a sufficient area of the backing sheet for the application of whatever fastening means are required to secure the panels to the wood frame structure. After the individual blocks 42 have been secured in place at the point of erection of the panels, the mortar applied therearound prevents cracking of the composition facing that might otherwise occur due to the difference in coefiicient of expansion between the composition in the facing and the backing sheet. There is no actual contact between the individual blocks 42 and the backing sheet 21. Furthermore, the arrangement of the interengaging clips or lugs for securing the individual blocks to the backing sheet is such that relative expansion or contraction between the blocks and the backing sheets is fully compensated for.

When the panels are erected over common brick tile, precast concrete, or when used as forms in the pouring of fresh concrete, all four sides of the backing sheet of each panel 25 may be flanged and bolted, riveted, clamped or pinched to the flanges of the adjacent sheets.

Although it is preferable to provide each prefabricated panel with a backing sheet, this is not essential where the keying material itself constitutes a sufficiently rigid reinforcement to permit a panel to be handled without a backing sheet. In the case of expanded metal lath, for instance, panels without backing sheets are sufliciently rigid, after the blocks have been molded and set, to permit the panels to be handled convenientiy during shipping and erection.

Much of the saving in cost of manufacture and installation, in the case of walls constructed in accordance with my invention as compared with ordinary masonry walls, is due to the lower labor cost. The application of mortar to the panels during their prefabrication can be done relatively inexpensively and eliminates much of the mortar laying that would otherwise have to be done on the job. While the prefabricated panels must be limited to sizes and weights that can be easily handled, they may nevertheless be sufficiently large to represent the equivalent of from to 100 common brick and still not be too large or heavy for handling. The saving of time in erecting a wall of such panels, over the time required to lay the corresponding number of ordinary brick, is very considerable.

It will, of course, be understood that various details of construction may be varied through a wide range Without departing from the principles of this invention and it is, therefore, not the purpose to limit the patent granted hereon otherwise than necessitated by the scope of the appended claims.

I claim as my invention:

1. A prefabricated building panel of veneered construction comprising a backing sheet, reticular material secured to said sheet, composition material keyed to said reticular material and molded into courses of blocks simulating masonry, a portion of said reticular material in at least one course near a marginal edge of said backing sheet being cut away to provide a space the size of about one-half a block, and securing and centering means on said backing sheet within said space for securing thereto an individual block, said marginal edge being ofiset to overlap the ad.

jacent marginal edge of another backing sheet when in assembled relation.

2. A prefabricated building panel of veneered construction comprising a backing sheet, reticular material secured to said sheet, composition 5 material keyed to said reticular material and molded into courses of blocks simulating masonry, a. portion of said reticular material in at least 

